Shipping case



Oct. 31, 1961 c. H. KEITH 3,0

SHIPPING CASE Filed Dec. 31, 1958 3 Sheets-Sheet 1 INVENTOR. CLIFFORD H.KEITH BY 4 TTORNI Y6 C. H. KEITH SHIPPING CASE Oct. 31, 1961 5Sheets-Sheet 2 Filed Dec. 31, 1958 u U n I u a I I I INVENTOR. CLIFFORDH. A's/7H Oct. 31, 1961 c. H. KEITH 3,006,523

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Fl 5 b CLIFFORD H. KEITH United States Patent ()fi ice 3,006,523Patented Oct. 31, 1961 3,006,523 SHIPPING CASE Clifford H. Keith,Atlanta, Ga., assignor, by mesne assignments, to The Mead Corporation,Dayton, Ohio, a corporation of Ohio Filed Dec. 31, 1958, Ser. No.784,184 13 Claims. (Cl. 229-15) This invention relates to a shippingcase and more particularly to a shipping case formed from a plurality ofindividual trays which are vertically nested and secured together toform an integral multi-tray case.

The mass packaging and shipping of fragile objects has been a difficultproblem to those who handle objects too delicate to be packed one uponanother in a conventional shipping case. Shallow cases have been used toreduce the number of layers of objects packaged, but these thin casesare of much smaller capacity than the conventional cases and thus manymore are required in order to handle an equal quantity of objects.Attempts have been made to devise cases in which a number of individualtrays are combined and secured together to approximate more nearly theshape and capacity of conventional shipping cases, but these multi-traycases require either an outside container surrounding the trays oradditional interlocking elements such as straps, wires or staples. Inany of these cases the additional cost of material and the expense ofcomplicated construction tend to minimize the saving in handling.

An example of the use of multi-tray cases is in the produce industrywhere items such as tomatoes, berries and many other vegetables andfruits would be damaged if packed in deep containers. These itemsrequire shallow packing and, in order to facilitate handling, it isdesirable to combine a plurality of shallow containers, such as trays,into an integral case,.

The present invention provides a mult-tray shipping case which overcomesthe disadvantages set out above. No outside container is required otherthan the trays themselves, as one of the trays is utilized to secure allthe trays together to form an integral case. No additional interlockingelements are required as the trays themselves are designed to nest witheach other in a rigid and structurally strong manner. Also, a cover isprovided with integral means for locking the cover on the case. Further,each of the elements can be formed from single pieces of stock andassembled without gluing or stitching.

These and other features of the present invention are described infurther detail below in connection with the accompanying drawings, inwhich:

FIG. 1 is a perspective view of a shipping case embodying the presentinvention;

FIG. 2 is a vertical sectional view taken along line 2-2 of FIG. 1;

FIG. 3 is a vertical sectional view taken along line 33 of FIG. 1;

FIG. 4 is a top plan view, partially in section of the shipping case ofFIG. 1 with the cover removed; and

FIG. 5 is an exploded perspective view, partially in section, of theshipping case of FIG. 1.

Referring to the drawings, a shipping case is indicated generally as 10,and consists of a bottom tray 11, an intermediate tray 12, a top tray 14and a cover 15. The trays are vertically nestable and the end walls 16of the bottom tray 11 extend over the end walls 18 of the top tray 14 tosecure the trays together, as will be described below. The cover 15extends across the top of the case and is 'removably locked thereon bylocking means formed integrally with the cover and case. The case, whenassembled for shipping, has somewhat the same outer appearance asconventional cases except for the exposed walls of the individual trays,thus the bottom tray 11 provides the bottom and end walls of the case,the side walls of the individual trays 11, 12 and 14 combine to form thesides of the case and the cover 15 serves its conventional purpose.

In the embodiment illustrated, the shipping case 10 is formed fromcorrugated paper board which is scored and folded to the desiredconfiguration. However, it is to be understood that the presentinvention may be practiced by utilizing many other materials, and,although scoring and folding are shown here, the scope of the inventionis not so limited, as any other convenient method of forming may beused.

The bottom tray 11 will first be described as it is the base upon whichthe other trays are nested and includes the means for securing the traystogether into an integral case. In the embodiment illustrated, thebottom tray 11 consists of a rectangular bottom 19, end walls 16 andside walls 20. The end walls 16 extend vertically upwardly from thebottom 19 along the outside of the other trays to the top of the endwalls 18 of the top tray 14 and have foldable portions 21 which arefolded inwardly over the top tray walls 18. These foldable portions 21are of approximately the same height as the top tray end walls 18, sothat when they are folded over along the inside of the top tray wallsthey will extend down into contact with the top tray bottom as explainedfurther below. A pair of latching feet 24 extend from the outer end ofeach foldable portion 21 and are engageable in latching slots 25 formedin the top tray bottom 22 adjacent the top tray end walls 18. Thelatching feet 24 and slots 25 interlock to retain the foldable portions21 in their folded positions and thus secure the trays 11, 12 and 14together to form an integral multi-tray case 10. This construction isillustrated in FIGS. 2 and 5.

The side walls 20 of the bottom tray 11 have inner wall sections 29extending from the tops thereof downwardly to the bottom 19 of thebottom tray 11, thus increasing the strength and rigidity of the loadbearing side walls 20. The inner wall sections 29 are latched in placeby feet 30 extending therefrom into slots 31 in the bottom 19 adjacentthe side walls 20. The end walls 18 and side walls 20 are interlocked bylateral arms 26 which extend from the end walls 18 between the sidewalls 20 and the inner wall sections 29.

Intermediate the ends of the side walls 20 of bottom tray 11 areupwardly extendable keying flaps 34. These flaps 34 are tapered upwardlyfor convenient engagement with the intermediate tray 12 to nest theintermediate tray 12 on the bottom tray 11. Directly below the keyingflaps 34 are ventilation openings 36 which permit the entry of air intothe interior of the tray to ventilate produce or other perishable goods.These openings 36 can also be used to grasp the tray for easy handling.

When the bottom tray 11 is formed from corrugated paper board, as in theembodiment illustrated, it may be cut, scored and folded from a singleblank of flat stock. .The blank is cut to the shape of the rectangularbottom 19 with wall forming flanges extending from each edge. Theseflanges are scored at their juncture with the bottom so as to befoldable into vertical positions to form the end walls 16 and side walls20. The end wall forming flanges are cut with the lateral arms 26extending therefrom, which are scored at their juncture with the endwalls 16 so as to be folded inside the side walls 20. The flanges thatform the side walls 20 are double formed at the ends of the foldedportions 21 and inner wall sections 29, respectively, and the latchingslots 31 are cut in the bottom 19 adjacent the scored juncture with theside walls 20 in line with latching feet 30.- The keying flaps 34 arecut from the inner wall sections 29 so that when the inner wall sectionsare folded back along the outer wall sections the flaps will remain asvertical continuations of the side walls 20. The ventilation openings 36are cut from the side walls 20 in alignment with the openings 38 of theinner Wall sections 29 formed by the removal of the keying flaps 34.Hand openings 32 are cut in the end 'walls 16 at an intermediate pointto facilitate handling of the completed case or of the bottom trayindividually.

To assemble the bottom tray, the end wall forming flanges are firstfolded along the scoring to vertical positions and the lateral arms 26folded inwardly to positions along the side edges of the bottom portion19. The side walls 20 are then folded vertically and the inner wallsections 29 folded inwardly over the lateral arms 26, the keying flaps34 remaining upright. Finally, the latching feet 30 are engaged in thelatching slots 31 to latch the side walls 20, and the end walls 16, inassembled positions. The bottom tray 11 is thus assembled to receive theother trays. From the above description it is apparent that the bottomtray of this invention may be simply and inexpensively formed and can beassembled simply and rapidly without gluing or stitching.

Referring now to the intermediate tray 12 and the top tray 14, it isapparent that they are of identical construction so that either tray canbe utilized as the top tray or as the intermediate tray. Also, it shouldbe noted that although the drawings illustrate a case with only oneintermediate tray it is clearly within the scope of the presentinvention to construct a case with several intermediate trays or with nointermediate tray. The number of intermediate trays to be used in eachcase is determined by the height of the bottom tray end walls 16.

The intermediate tray 12 of the embodiment illustrated comprises arectangular base portion 39, from which side walls 40 and end walls 41extend vertically upward. The base portion 39 has approximately the samedimensions as the bottom 19 of the bottom tray 11 and the end walls 41of the intermediate tray are in line with the bottom tray end walls 16so that when inserted between the bottom tray end walls the intermediatetray will be firmly nested in place with its end walls 41 adjacent andinside of the end walls 16 of the bottom tray 11.

Lateral arms 42, similar to the lateral arms 26 of the bot-tom tray endwalls 16, extend from the intermediate tray end walls 41 forinterlocking engagement in the side Walls 40, which are similar inconstruction to the bottom tray side walls 20. Thus the side walls 40are formed with inner sections 45 extending downwardly to the baseportion 39 with latching feet 46 thereon for engagement in latchingslots 48 formed in the base portion 39 adjacent the side walls 40 in thesame manner as the above described latching slots 31 in the bottom 19 ofthe bottom tray 11. Also, keying flaps 49 and ventilation openings 50are formed at the side walls 40 similar to the flaps 34 and openings 36of the bottom tray 11. In addition, latching slots 25 are formed in thebase portion 39 adjacent the end walls to engage the latching feet 24 ofthe folded bottom end wall portions 21 when the tray structure is usedas a top tray 14.

When the inner wall sections 45 of the side walls 40 are folded backover the lateral arms 42 of the end walls 41, they are parallel to theside walls 40 and spaced therefrom by the lateral arms 42. As seen inFIG. 5, the lateral arms 42 do not extend across the area which is invertical alignment with the keying flaps 49. Thus, cavities 51 areformed between the side walls 40 and the inner wall section 45 below thekeying flaps 49. These cavities 51 are provided to receive the keyingflaps 49 of a subjacent tray or the keying flaps 34 of the bottom tray.In order that the cavities 51 can receive the keying flaps, flapreceiving slots 52 are cut in the base portion 39 adjacent the sidewalls 40 and vertically aligned with the cavities 51 so that the keyingflaps 49 of the subjacent tray may pass therethrough into the cavities.To further facilitate the receipt of the flaps 49, guide tabs 54 areformed as downward extensions of the outer wall sections 40. These guidetabs 54 engage the flaps 49 and guide their entry into the slots 52 andcavities 51. The guide tabs may conveniently be formed from the portioncut out to provide the flap receiving slots 52. Thus, the cut formingthe slot can be made before folding the outer end walls into thevertical positions and the material cut out will fold with the outerwall sections to become guide tabs.

When constructing the trays from corrugated paper board, theintermediate and top trays 12 and 14 are formed from single blanks in amanner similar to the formation of the bottom tray 11. Thus, arectangular base portion 39 is formed with wall forming flangesextending from each edge. The flanges are scored at their junctures withthe base portion for'folding into vertical positions to become sidewalls 40 and end walls 41. The end walls 41 are cut with lateral arms 42extending therefrom a distance substantially equal to the distancebetween the end walls 41 and the adjacent keying flaps 49 of the sidewalls 40. The flanges which form the side walls are laterally doublescored to form the inner wall sections 45 thereon, and the keying flaps49 are cut from the inner Wall sections 45 so that when the inner wallsections are folded along the double scoring the flaps will remain asvertical extensions of the side walls.

The inner wall sections 45 are cut with the latching feet 46 extendingtherefrom and the latching slots 48 and 25 are cut from the base portion39 adjacent the side wall flanges and end wall flanges in line with thelatching feet 46 and 24, respectively. The flap receiving slots 52 arecut from the base portion 39 adjacent the side wall flanges. in linewith the keying flaps 49, but the sides of the slots adjacent the sidewall flanges are not cut so that the cut out material will fold with theside walls 40 to form depending continuations on the outside of theslots. These continuations become the guide tabs 54 described above.

The ventilation openings 50 are cut in the outer wall sections 44adjacent the portion of the inner wall sections 45 which were cut awayto form the keying flaps 49, thus air may pass through the ventilationopenings 50 into the interior of the trays. These ventilation openings50 also serve as hand holds for easy grasping and handling of the trays.

The cut and score blank, as described above, is folded to form anintermediate or top tray by first upwardly folding the end wall flangesinto vertical positions with the lateral arms 4'2 folded to extend alongthe juncture of the side wall flanges and the base portion 39. The sidewall flanges are similarly upwardly folded to vertical positions withthe guide tabs 54 folded downwardly into guiding positions andsimultaneously forming the flap receiving slots 52. The inner wallsections 45 are then folded along the double scoring over the lateralarms 42 to positions parallel to and spaced inwardly from the side walls40 forming the flap receiving cavities 51 in the spaces between the endsof the lateral arms 42 vertically adjacent the Ifiap receiving slots 52.When the inner wall sections 45 are folded along the double scoring asdescribed, the keying flaps 49, which were cut from the inner wallsections 45, remain upright as extensions of the side walls 40. Finally,the latching feet 46 (FIG. 5) are inserted in the slots 48 to latch theside walls in place. When the tray described above is being used as atop tray'14 instead of an intermediate tray 12, the ventilation openings50 become part of the cover locking means and the keying flaps 49 arebent inwardly by the cover 15, reacting against the cover to urge itupwardly, in a locked position, as will be described. Also, the slots 25in the top tray bottom, which were superfluous with the intermediatetray, are now used to receive the feet 24 of the folded portions 21 ofthe bottom tray end walls 16.

The cover 15 of the shipping case 10 fits over the top tray 14 andconsists of a rectangular cover portion 55, side walls 56 and end walls58. The cover portion 55 has approximately the same dimensions as thetop tray 14 so that the side and end walls 56 and 58, which depend fiomthe edges of the cover portion, overlay the side and end walls 40 and 18of the top tray 14. The side walls 56 have inner sections 60 thereonextending upwardly and inwardly with latching feet 61 engaged inlatching slots 62 formed in the cover portion 55. The side and end walls56 and 58 of the cover 15 are interlocked in the same manner as the sideand end walls of the trays, thus the end walls 58 are provided withlateral arms 64 extending between the side walls 56 and inner sections60.

As seen in FIG. 5, the inner sections 60 of the side walls 56 extendinto contact with the cover portion 55 to add strength and rigidity tothe cover 15. However, there are formed on the upper central portions ofthe inner sections 60, a pair of upwardly and slightly inwardlyextending locking tabs 69 (FIGS. 2 and 5) the upper edges 66 of whichautomatically engage in or through the ventilation openings 50 when thecover 15 is placed over the upper tray 14. These tabs 69 are formed bycutting wide W-shaped slots 68 in said inner wall sections 60 and byremoving the W-shaped Wall portions lying within and above the W-shapedslot. When the cover 15 is placed on the case and the side walls 56 aresprung outwardly, the locking tab 69 will swing downwardly and inwardlyso as to engage into the ventilation openings 50. Upon release of theside Walls 56, the tabs will tend to return to vertical positions,further engaging in the openings to lock the cover on the case. Tounlock, the sides 56 must once again be deformed until the tabs 69 havebeen withdrawn from the openings.

As was mentioned previously, the keying flaps 49 of the top tray 14 arebent inwardly by the cover 15 when the cover is forced down on the case.react against the cover to urge it upwardly and facilitate the lockingaction of the locking tabs 69 in the openings 50. This is illustrated inFIG. 3.

The cover 15 of the embodiment illustrated is formed from corrugatedpaper board, as were the trays, and the cover can similarly be formedfrom a single piece of stock. Thus a single blank is cut and scored toform the rectangular cover portion 55 with flanges extending from eachedge. The flanges are scored at their juncture with the cover portionfor folding downwardly to form depending walls. The end walls 58 are cutwith the lateral arms 64 extending therefrom and scored for folding thearms into engagement with the side Walls 56. The side walls are doublescored laterally to form the inner sections 60 thereon, and the innersections are cut with the latching feet 61 and the U-shaped slots 65 toform the locking tabs 69. Also, the cover portion 55 is cut to form thelatching slots 62 adjacent the inner wall sections in line with thelatching feet 61.

The cover 15 is simply assembled from the cut and scored blank byfolding the end walls 58 downwardly, the lateral arms 64 inwardly, theside walls 56 downwardly and the inner side wall sections 60 over thelateral arms 64 until the latching feet 61 are engaged in the latchingslots 62.

Since all of the trays and the cover of the present embodiment can beformed from fiat blanks, a tremendous saving in space is possible whenshipping or storing the empty cases. They can be shipped or stored inknock-down form and assembled prior to use. As the assembly proceduresare simple and rapid, the unskilled user can quickly assemble the traysand covers at the point of packaging and needs no glue or staples.

When the trays and cover have been assembled and the trays packed withobjects, the intermediate tray 12 is simply lowered between the endwalls 16 of the bottom tray 11, which guide the nesting of the trays sothat the cavities -51 of the intermediate tray 12 will be aligned withthe keying flaps 34 of the bottom tray. The intermediate tray issupported by the side walls 20 of the bottom tray and since the flaps 34are locked in vertical positions between the inner and outer wallsections 45 and 44, the trays are locked in alignment. The top tray 14is similarly nested between the end walls 16 of the bottom tray 11 andkeyed on top of the intermediate tray 12. The trays are secured as anintegral multi-tray case by folding the folded portions 21 of the endwalls 16 over the top tray end walls 18 and latching the feet 24 in theslots 25. Finally, the cover 15 is placed over the case 10 and lockedthereon by insertion of the locking tabs 69 inthe ventilation openings50 of the top tray 14.

The multi-tray construction of this invention is adaptable to other usesthan for fragile objects only. Thus it readily lends itself to shippinga selection of different objects, such as oranges in one tray,grapefruit in another tray, and tangerines in another.

From the above description it is obvious that the present inventionprovides a multi-tray shipping case which requires no additionalmaterial except the extended bottom tray end walls; which hasinterchangeable top and intermediate trays; and which has nesting means,tray securing means and cover locking means all integral with the traysand covers so as to eliminate any additional elements. Further, thetrays and covers can each be formed from single blanks such as by diecutting and there is no gluing or stitching required to assemble thetrays and cover from the cut blanks.

While this invention is susceptible of embodiments in many differentforms, there is shown in the drawings and is herein described in detailone specific embodiment, with the understanding that the presentdisclosure is to be considered as an exemplification of the principlesof the invention and is not intended to limit the invention to theembodiment illustrated, the scope of the invention being defined in theappended claims.

I claim:

. 1. A multi-tray shipping case, comprising bottom, top and intermediatetrays vertically nestable to form a multitray case, the bottom trayhaving walls extending upwardly into engagement with the top tray; andlatching means for detachably latching said walls to'said top tray toform an integral case.

2. A multi-tray shipping case, comprising bottom, top and intermediatetrays vertically nestable to form a multitray case, the bottom trayhaving Walls extending upwardly into engagement with the top tray;latching means for detachably latching said walls to said top tray toform an integral case; a removable cover mountable over the top tray;and locking means for detachably locking said cover on the case.

3. A multi-tray shipping case, comprising a plurality oftraysv'ertically nestable to form a multi-tray ease, the top tray havingupstanding walls, the bottom tray having walls aligned with the walls ofsaid top tray, the bottom tray walls extending upwardly to the top ofthe top tray walls and having a portion foldable over said top traywalls; and latching means for detachably latching said foldable portionto the top tray thereby forming an integral case.

4. A multi-tray shipping case, comprising a plurality of traysvertically nestable to form a multi-tray case, the

top tray having upstanding walls, the bottom tray having walls alignedwith the walls of said top tray, the bottom tray walls extendingupwardly to the top of the top tray walls and having a portion foldableover said top tray walls, said foldable portion having latching feetextending therefrom and said top tray having latching slots shaped toreceive said feet to removably latch said bot- 7 tom tray walls to the'top tray, thereby forming an integral case. e

5. A multi-tray shipping case, comprising a plurality of traysvertically nestable to form a' multi-tray case, 'the top tray havingupstanding walls, the bottom tray having walls aligned with the walls ofsaid top tray, the bottom tray walls extending upwardly to the top ofthe top tray walls and having portions foldable over said top traywalls, said foldable portions being of substantially the same height asthe top tray walls and having latching feet extending therefrom, saidtop tray having latching slots formed in its bottom adjacent said toptray walls shaped to receive said feet to removably latch said bottomtray walls to the top tray walls, thereby forming an integral case.

6. A multi-tray shipping case, comprising bottom, top and intermediatetrays vertically nestable' to form a multitray case, the bottom trayhaving walls extending upwardly into engagement with the top tray;latching means for detachably latching said walls to said top tray toform an integral case; and a removable cover mountable over the top trayand having a locking tab, said top tray hav ing a locking slot forreceiving said locking tab to lock the top on the case.

7. A multi-tray shipping case, comprising a plurality of traysvertically nestable to form a multi-tray case, the bottom tray havingwalls extending upwardly into engagement with the top tray; latchingmeans for detachably latching said walls to said top tray to 'form anintegral case; a removable cover mountable over the top tray and havinga locking tab, said top tray having a locking slot for receiving saidlocking tab to lock the cover on the case and a flap on said top trayadjacent said locking slot and normally extending upwardly, the flapbeing forced from its normal position into a less upwardly extendingposition by the cover and thereby reacting against the cover to urge thecover upwardly and lock the locking tabs in the locking slots.

8. A shipping case, comprising a plurality of vertically nested trayswith the top tray having upstanding walls, said walls having lockingslots formed therein; a removable cover mountable over the top tray andhaving depending walls overlaying the walls of the top tray andextending beyond said lockingslots; and locking tabs extending from thewalls of the cover and engageable in the locking slots when the cover ismounted on the case, thereby locking the cover on' the case.

'9. A shipping case, comprising a body portion'having upstanding walls,said walls having locking slots formed therein; a removable covermountable over said body portionand having depending walls overlayingthe walls of the body portion and extending beyond said locking slots;and flaps normally extending upwardly from the upstanding walls of thebody portion adjacent said locking slots, the llaps being forced by thecover to less upwardly extending positions and thereby reacting againstthe cover to urge the cover upwardly and lock the locking tabs in thelocking slots.

10. A shipping case, comprising a body. portion having upstanding walls,said walls having horizontal locking slots formed therein adjacent thetop of the walls; a removable cover mountable over said body portion andhaving depending walls overlaying the walls of the body portion andextending beyond said locking slots, said walls of the cover having endportions folded back along the walls adjacent the body portion, eachsaid folded back end portion having a horizontal tab forming slotadjacent one of said horizontal locking slots and vertical slotsextending downwardly from the ends of said tab forming slots forming atab which is engageable in the locking slot to lock the cover on thebody portion.

11. A blank foldable to form a cover for a shipping case or the like andincluding tabs engageable in horizontal locking slots of the case tolock the cover on the case, the blank, comprising a cover portion; wallforming flanges extending from said cover portion and scored at theirjuncture with the cover portion so as to be foldable to form walls;foldback end portions extending from said wall forming flanges and beingdouble scored at the juncture with the flanges, each said end portionhaving a generally wide W-shaped slot formed adjacent its outer end withthe base of the wide W-shaped slot parallel with the double crease toform a tab shaped so that when the blank is folded along the creases thetab extends upwardly adjacent the locking slot of the case and isengageable therein to lock the cover on the case.

12. A tray vertically nestable with similar trays to form a multi-traycase, the tray comprising a base portion; outer wall sections extendingfrom said base portion and folded into vertical positions; inner wallsections extending from said outer wall sections and folded inwardly tovertical positions parallel to and spaced from the outer wall sectionsforming cavities therebetween; keying flaps formed from said inner wallsections before folding, said flaps being vertical extensions of saidouter wall sections, guide tabs formed from said base portion adjacentsaid outer Wall sections and folded with the outer wall sections to formvertical continuations of the outer walls sections, the guide tabs beingvertically aligned with the keying tabs, the folding of the guide tabswith the outer wall sections provides slots in the base portionvertically aligned with the keying tabs, the guide tabs, slots andcavities being shaped to engage the keying flaps of a verticallyadjacent tray.

13. A tray vertically nestable with similar trays to form a multi-traycase, the tray comprising a base portion; walls extending verticallyfrom said base portion; a keying fiap extending from one of said walls,said base portion having a "flap receiving slot adjacent one wall andvertically aligned with said flap, said one wall having a flap receivingcavity vertically aligned with said slot, said slot and cavity beingshaped to receive the keying flap of a vertically adjacent tray; and aguide tab on the wall extending outwardly adjacent the slot of the baseportion and extending vertically beyond the base portion to guide thereceipt of the-keying flap of the vertically adjacent tray.

References Citedin the file of this patent UNITED STATES PATENTS2,583,673 Storey Jan. 29, 1952 2,745,589 Daley et a1. May 15, 19562,843,307 Goltz July 15, 1958 FOREIGN PATENTS 783,932 Great Britain Oct.2, 1957

